Appliance water valve assembly and associated method

ABSTRACT

A water valve assembly includes a valve body having defined therein (i) an inlet, (ii) an outlet, (iii) a central cavity, and (iv) a component access opening, wherein fluid advancing into the valve body through the inlet must pass through the central cavity before exiting out of the valve body through the outlet, and further wherein the component access opening is configured so that a valve component may be advanced into the central cavity through the component access opening. The water valve assembly further includes a retaining bracket having a retaining portion positioned in relation to the valve body so as to block advancement of the valve component from the central cavity to a location outside of the valve body through the component access opening.

[0001] This application is a continuation of co-pending Application Ser.No. 09/621,438, filed on Jul. 21, 2000.

CROSS REFERENCE

[0002] Cross reference is made to copending U.S. patent application Ser.No. 09/621,270, entitled “Flow Control Device Having a Lip Seal andCompressible Bypass Pads and Associated Method for Operating anAppliance Water Valve” by Michael R. DuHack and Ser. No. 09/621,437,entitled “Integrated Filter and Noise Suppressor Device for a WaterValve Assembly and Associated Method for Operating the Same” by MichaelR. DuHack, both of which are assigned to the same assignee as thepresent invention and both of which are filed concurrently herewith. Thedisclosure of each of the above-identified patent applications is herebytotally incorporated by reference in their entirety.

TECHNICAL FIELD OF THE INVENTION

[0003] The present invention relates generally to appliance water valvesassociated methods for making the same.

BACKGROUND OF THE INVENTION

[0004] Electrically operated water valves are commonly used in manyhousehold appliances such as a refrigerator for providing a flow ofwater to appliance components such as icemakers and water dispensingunits. Such appliance water valves are generally controlled by acontroller associated with the appliance thereby providing a flow ofwater, at a predetermined flow rate, for use by the appliance.

[0005] Due to the highly competitive nature of the appliance industry,it has become increasingly necessary to reduce costs associated withmanufacture of the appliances. As with any type of manufacturing, oneway to reduce the cost associated with an article of manufacture is toreduce the cost of the components from which the article of manufactureis constructed. Hence, in the particular case of the appliance industry,one way of reducing the cost associated with the manufacture of a givenappliance is to reduce the cost of the components from which theappliance is constructed.

[0006] Accordingly, it has become increasingly necessary to reduce thecost of, for example, the water valve which is assembled into arefrigerator. Several problems exist with current assembly methods forappliance water valves which tend to increase costs associated with thevalve. For example, heretofore designed water valves are assembled byuse of weldments and fasteners such as screws. The manufacturingprocesses associated with the use of weldments and fasteners are oftendifficult to control and monitor thereby increasing costs associatedwith manufacture of the water valve. In particular, the use of fastenershas heretofore been difficult and expensive to automate therebynecessitating a labor intensive manual assembly process for installingthe fasteners. Moreover, weldments have typically undesirably requiredrelatively tight tolerances in both component design and assemblytechniques thereby necessitating that use of relatively expensivemanufacturing techniques to work with such tight tolerances.

[0007] In addition to reducing costs associated with the water valve,there also exists an increasing need to increase performance of thewater valve. In particular, it is becoming increasingly important forappliance water valves to be capable of providing for a relativelyconstant flow rate across a broader inlet water pressure range. Inparticular, heretofore designed elastomeric flow control devices havetypically been unable to produce a constant flow rate a relatively lowinlet water pressures (e.g. 10-20 psi). As a result of this, certainflow control devices have been designed with features which provide fora bypass flow of water around the flow control device. While theseattempts have produced somewhat favorable results at low pressures, thebypass flow of water around the flow control device also exists at highwater pressures thereby undesirably providing for a flow rate at highwater pressures which exceeds the desired flow rate.

[0008] What is needed therefore is an appliance water valve whichovercomes one or more of the above-mentioned drawbacks. What isparticularly needed is an appliance water valve that is relatively easyto assemble and does not require the use of weldments or fasteners. Whatis also particularly needed is an appliance water valve that providesfor a substantially constant flow rate at relatively low inlet waterpressures.

SUMMARY OF THE INVENTION

[0009] Pursuant to one embodiment of the present invention, there isprovided a water valve assembly. The assembly includes a valve bodyhaving defined therein (i) an inlet, (ii) an outlet, (iii) a centralcavity, and (iv) a component access opening, wherein fluid advancinginto the valve body through the inlet must pass through the centralcavity before exiting out of the valve body through the outlet, andfurther wherein the component access opening is configured so that avalve component may be advanced into the central cavity through thecomponent access opening. The assembly further includes a retainingbracket having a retaining portion positioned in relation to the valvebody so as to block advancement of the valve component from the centralcavity to a location outside of the valve body through the componentaccess opening.

[0010] It is therefore an object of the present invention to provide anew and useful appliance water valve.

[0011] It is moreover an object of the present invention to provide animproved appliance water valve.

[0012] It is a further object of the present invention to provide a newand useful method of making an appliance water valve.

[0013] It is also an object of the present invention to provide animproved method of making an appliance water valve.

[0014] The above and other objects, features, and advantages of thepresent invention will become apparent from the following descriptionand the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIGS. 1 and 2 are perspective views of an appliance water valveassembly which incorporates the features of the present inventiontherein;

[0016]FIG. 3 is an exploded perspective view of the water valve assemblyof FIGS. 1 and 2;

[0017]FIG. 4 is a cross sectional view taken along the line 4-4 of FIG.1, as viewed in the direction of the arrows;

[0018]FIG. 5 is an elevational view of the mounting bracket of the watervalve assembly of FIGS. 1 and 2;

[0019]FIG. 6 is a cross sectional view of the valve body of FIGS. 1 and2;

[0020]FIG. 7 is an enlarged view of a portion of FIG. 6 which isencircled and indicated as FIG. 7;

[0021]FIG. 8 is an enlarged view of the inlet portion of the water valveassembly of FIG. 4;

[0022]FIG. 9 is a view similar to FIG. 8, but showing the inlet portionin a perspective cross sectional view;

[0023]FIG. 10 is an enlarged plan view of the flow control device of thewater valve assembly of FIGS. 8 and 9;

[0024]FIG. 11 is a cross sectional view of the flow control device takenalong the line 11-11, as viewed in the direction of the arrows;

[0025]FIG. 12 is a perspective view similar to FIG. 1, but showing adual outlet water valve assembly which incorporates the features of thepresent invention therein;

[0026]FIG. 13 is a fragmentary cross sectional view similar to FIG. 4,but showing the water valve assembly configured with an integratedfilter and noise suppressor (note that the flow control device and thewasher have been removed from FIG. 13 for clarity of description);

[0027]FIGS. 14 and 15 are enlarged perspective views of the integratedfilter and noise suppressor of the water valve assembly of FIG. 13;

[0028]FIG. 16 is a plan view of the integrated filter and noisesuppressor of FIGS. 14 and 15;

[0029]FIG. 17 is an elevational view of the integrated filter and noisesuppressor of FIG. 16, as viewed from the upstream side thereof;retainer 28, a lower pole plate frame 30, a guide tube 32, and anarmature 34. The valve actuator assembly 22 is provided to selectivelyallow for the advancement of a flow of water out the water outlet 16. Inparticular, the armature 34 is disposed in the guide tube 32 and isbiased against a valving surface 36 (see also FIG. 6) by a spring 38thereby urging a seal insert 40 associated with the armature 34 againsta valving surface 36. The seal insert 40 is made of a flexible material,such as ethylene propylene (EP) rubber thereby providing desirablesealing characteristics when biased against the valving surface 36.

[0030] Hence, when the valve actuator assembly 22 is in a closedposition, such as shown in FIG. 1, the seal insert 40 of the armature 34is biased against the valving surface 36 thereby preventing water fromflowing out of the central cavity 42 and through the water outlet 16.However, when the valve actuator assembly 22 is moved to an openposition, i.e. a position in which the seal insert 40 of the armature 34is spaced apart from the valving surface 36, water is permitted to flowout of the central cavity 42 and through the water outlet 16 therebyproviding for a flow of water out of the water outlet 16 and into thefill line of the appliance component.

[0031] It should be appreciated that the solenoid coil 26 is selectivelyactuated to position the valve actuator assembly 22 in its openposition. In particular, actuation of the solenoid coil 26 by thecontroller of the appliance (not shown) generates a magnetic field whichurges the armature 34 upwardly (as viewed in FIG. 4) thereby positioningthe valve actuator assembly 22 in its open position in which water isadvanced out of the water outlet 16. Deactuation of the solenoid coil 26by the appliance controller removes the magnetic field thereby allowingthe spring bias generated by the spring 38 to urge the armaturedownwardly (as viewed in FIG. 4) such that the seal insert 40 is seatedon the valving surface 36.

[0032] As shown in FIGS. 3 and 4, the water valve assembly 10 alsoincludes a number of valve components which are positioned within thecentral cavity 42 proximate to the water inlet 20. In particular, thewater valve assembly 10 also includes an end cap 44, a filter screen 46,a noise suppressor 48, a flow control device 50, and a washer 52. Thefilter screen 46 inhibits debris particles, which may be contained inthe incoming residential water flow, from reaching the noise suppressor48, the flow control device 50, the valve actuator assembly 22, or othercomponents associated with the water valve assembly 10.

[0033] The flow control device 50 is made of flexible material such asethylene propylene (EP) rubber, and has a central passage 54 definedtherein. The flow control device 50 flexes or deforms in response tovariations in inlet water pressure exerted on an upstream surface orface 56 thereof. In particular, a higher inlet water pressure on theupstream face 56 causes a greater amount of flexing or deformity of theflow control device 50 thereby reducing the diameter of the centralpassage 54. A lower inlet water pressure exerted on the upstream face 56causes the flexing or deformity of the flow control to be reducedthereby enlarging, or even maximizing, the diameter of the centralpassage 54. As shall be discussed below in greater detail, the flowcontrol device 50 provides for a relatively constant flow rate of wateracross a relatively broad range of inlet water pressures includingrelatively low inlet water pressures in the range of less than 20 psi.

[0034] The washer 52 has a washer orifice 140 defined therein andprovides a surface on which the flow control device 50 is supported. Thewasher 52 is typically made of a rigid material such as plastic orstainless steel.

[0035] The noise suppressor 48 is provided to reduce the amount ofcavitation, and hence the amount of noise, generated by the flow ofwater being advanced through the appliance water valve assembly 10. Thenoise suppressor 48 is made from a plastic material, such aspolypropylene.

[0036] As shown in FIGS. 1-4, the water valve assembly 10 also includesa retaining bracket 58. The retaining bracket 58 is generallyconstructed of metal and is provided to retain the valve components 44,46, 48, 50, and 52, along with a pair of O-ring seals 64, within thecentral cavity 42 of the valve body 12 once the components and theO-ring seals have been advanced through a component access opening 68defined in the valve body 12. In particular, the retaining bracket 58has a flange 60 defined therein which is advanced through a pair ofbracket-receiving openings such as bracket-receiving slots 62 defined inthe valve body 12. Once advanced through the bracket-receiving slots 62,a distal end portion 66 of the flange 60 is crimped, bent, or otherwiseformed in order to prevent the flange 60 from being removed from thebracket-receiving slots 62. As shown in FIGS. 1, 2, and 4, the distalend portion 66 of the flange 60 is preferably crimped into asubstantially L-shaped configuration in order to prevent the flange 60from being removed from the bracket-receiving slots 62. Hence, whenretained by the retaining bracket 58, the end cap 44, along with itsassociated O-rings 64, sealingly engages the valve body 12 so as toprevent water from advancing out of the component access opening 68.

[0037] When installed in such a manner, the flange 60 retains the endcap 44 (and hence the filter screen 46, the noise suppressor 48, theflow control device 50, and the washer 52) in the central cavity 42 ofthe valve body 12. It should be appreciated that the flange 60 mayretain the end cap by actually contacting the end cap 44, or may retainthe end cap 44 by being slightly spaced apart from the end cap 44, butpreventing the end cap 44 from moving beyond the predetermined distancefrom which it is separated from the flange 60.

[0038] As shown in FIGS. 3 and 4, the retaining bracket 58 also has apair of locking tabs 70 defined therein. The locking tabs 70 function tofacilitate retention of retaining bracket 58 to the valve body 12. Inparticular, as shown in FIGS. 1-2 and 4, once the flange 60 has beenadvanced through the bracket-receiving slots 62, a distal end portion 72of the locking tabs 70 is crimped, bent, or otherwise formed in order toprevent the flange 60 from being removed from the bracket-receivingslots 62. As shown in FIGS. 1-2 and 4, the distal end portion 72 of eachof the locking tabs 70 is preferably crimped in the general direction ofthe outlet 16 so as to assume a substantially L-shaped configurationthereby contacting a retaining shoulder 74 defined in the valve body 12.It should be appreciated that such contact with the retaining shoulders74 by the locking tabs 70 prevents the flange 60 from being removed fromthe bracket-receiving slots 62.

[0039] It should be appreciated that the respective end portions 66, 72of the flange 60 and the locking tabs 70 may be crimped in any one ofnumerous manners. Preferably, the respective end portions 66, 72 of theflange 60 and the locking tabs 70 are simultaneously crimped by a singledie or other type of forming tool during manufacture of the water valveassembly 10.

[0040] The retaining bracket 58 also functions to retain the fitting 18,along with an associated number of sealing rings 84, in the fluidopening 14. In particular, as shown in FIG. 3, the fitting 18 hasdefined therein a substantially flat flange 76 which surrounds adouble-D shaped protrusion 78. When the retaining bracket 58 is securedto the valve body 12, the double-D shaped protrusion 78 is receivedthrough a corresponding double-D shaped opening 80 defined in theretaining bracket 58. As the retaining bracket 58 is advanced downwardly(as viewed in FIG. 3), an upper flange 82 thereof contacts the flange 76of the fitting 18 thereby urging the fitting 18 downwardly so as toretain the fitting 18 in the fluid opening 14. Once the fitting 18 hasbeen secured to the valve body 12 in such a manner, a disposable fittingcap 124 may be installed onto the threads of the inlet fitting 18 inorder to protect the threads of the fitting 18 during shipment or otherhandling of the water valve assembly 10.

[0041] Hence as described herein, each of the inlet valve components 44,46, 48, 50, and 52, the inlet fitting 18, and the associated seals 64,84 are retained in the valve body 12 by the retaining bracket 58. Such aconfiguration provides numerous advantages to the water valve assembly10 of the present invention. For example, use of the retaining bracket58 eliminates the need for fasteners such as bolts or weldments in theassembly of this portion of water valve assembly 10. Such elimination offasteners and weldments simplifies the manufacturing process associatedwith construction of the water valve assembly 10 since the retainingbracket 58 may be secured to the valve body 12 by a relatively simplecrimping technique as described above. Moreover, such elimination offasteners also reduces the component count associated with the watervalve assembly 10 thereby further reducing costs associated therewith.

[0042] The valve actuator assembly 22 of the water valve assembly 10 mayalso be assembled without the use of fasteners or weldments. Inparticular, the armature 34 and the biasing spring 38 are first insertedinto the guide tube 32. Thereafter, the guide tube 32 is snapped ontothe valve body 12. In particular, the lower portion of the guide tube 32has a number of cantilevered snaps 88 defined therein (see FIGS. 2 and4). The snaps 88 engage a bottom surface 90 of the valve body 12 so asto secure the guide tube 32 to the valve body 12. It should beappreciated that a number of washers and O-rings 86 may be utilized toseal the guide tube 32 to the valve body 12.

[0043] Once the guide tube 32 has been secured to the valve body 12(with the armature 34, the washers and O-rings 86, and the biasingspring 38 captured therein), the lower pole plate frame 30 is loweredonto the guide tube 32. In particular, a tube portion 92 of the guidetube 32 is received through a tube opening 94 defined in the lower poleplate frame 30 such that a number of locating tabs 96 defined in thelower pole plate frame 30 may be positioned in a corresponding number oflocating slots 98 defined in an upper surface of the guide tube 32. Inorder to secure the lower pole plate frame 30 to the valve body 12, apair of L-shaped locking tabs 100 defined in the lower pole plate frame30 are folded inwardly toward one another so as to be captured by aninverted L-shaped member 102 defined in the valve body 12. It should beappreciated that the locking tabs 100 may be simultaneously folded orotherwise formed by a single die or other forming tool.

[0044] Once the lower pole plate frame 30 has been secured to the valvebody 12, the retainer 28 is then lowered onto the lower pole plate frame30 and the guide tube 32. In particular, the tube portion 92 of theguide tube 32 and the upper portion of the lower pole plate frame 30 isreceived through a retainer opening 106 defined in the retainer 28. Theretainer 28 is secured to the guide tube 32 by use of a number oflocking tabs 108 which are defined in the guide tube 32 and are receivedthrough a corresponding number of openings 110 defined in the retainer28 (see FIGS. 2 and 4). It should be appreciated that when secured tothe guide tube 32 in the manner described above, a downwardly extendingskirt portion 112 of the retainer 28 functions to keep the cantileveredlocking tabs 88 of the guide tube 32 from being inadvertently disengagedfrom the bottom surface 90 of the valve body 12.

[0045] The solenoid coil 26 is then lowered onto the partially assemblywater valve assembly 10. In particular, the tube portion 92 of the guidetube 32 and the upper portion of the lower pole plate frame 30 isreceived through a solenoid opening 114 defined in the solenoid coil 26.

[0046] The solenoid coil 26 is secured to the water valve assembly 10 bythe upper pole plate frame 24. In particular, a downwardly extending,cylindrically shaped pole portion 116 of the upper pole plate frame 24is received into the solenoid opening 114 of the solenoid coil 26. Atthe same time, a locking opening 118 defined in a lower flange 120 ofthe upper pole plate frame 24 is received around an upwardly extending,cylindrically shaped protrusion 122 defined in the lower pole plateframe 30 (see FIGS. 3 and 4). The upper wall portion of the protrusion122 is then swaged or otherwise deformed so as to capture the lowerflange 120 of the upper pole plate frame 24 thereby securing the upperpole plate frame 24 and hence the solenoid coil 26 to the water valveassembly 10.

[0047] Hence, as described above, it should be appreciated that thevalve actuator assembly 22 may be assembled without the use of fastenersor weldments thereby facilitating ease of assembly of the water valveassembly 10. As described above, such elimination of fasteners andweldments simplifies the manufacturing process associated withconstruction of the water valve assembly 10 by, amongst other things,providing for enhanced automation of the assembly process therebyreducing, if not eliminating, the need for more expensive manualassembly techniques.

[0048] Referring now to FIGS. 8 and 9, the inlet portion of the watervalve assembly 10 is shown in greater detail. As described above, theflow control device 50 provides for a relatively constant flow rate ofwater through the water valve assembly 10 across a relatively broadrange of inlet water pressures. In particular, as shall now be describedin greater detail, the flow control device 50 of the present inventionselectively provides for a bypass flow of water around the periphery ofthe flow control device 50 at relatively low water pressures, butprevents such a bypass flow of water around the periphery of the flowcontrol device 50 at higher water pressures.

[0049] As shown in FIGS. 10 and 11, the flow control device 50 issubstantially disk shaped and includes a body 130 having the centralpassage 54 extending therethrough. As shown in FIG. 11, the body 130 ofthe flow control device 50 has defined therein the upstream face 56 anda downstream surface or face 128. A sealing member such as a sealing lip126 is integrally formed or otherwise secured around the periphery ofthe downstream face 128 of the body 130. The flow control device 50 alsohas defined therein a number of bypass pads 132 which extend outwardlyfrom the downstream face 128 of the body 130. Although the flow controldevice 50 is herein described and shown in the drawings to include threebypass pads 132, it should be appreciated that both the size and numberof bypass pads 132 included in a particular design of the flow controldevice 50 may be altered to fit the needs of a given design of the watervalve assembly 10.

[0050] As shown in FIGS. 6 and 7, the valve body 12 has a number ofbypass channels 134 defined therein. The bypass channels 134 cooperatewith the flow control device 50 in order to provide for a bypass flow ofwater around the periphery of the flow control device 50 at relativelylow inlet water pressures. In particular, at relatively low inlet waterpressures (e.g., less than 20 psi), a sealing surface 136 defined in thesealing lip 126 of the flow control device 50 is spaced apart from ashoulder 138 of the bypass channels 134 (see FIGS. 7, 8, 9, and 11).This allows water advancing through the central cavity 42 of the valvebody 12 to not only advance through the central passage 54 of the flowcontrol device 50, but also advance through the bypass channels 134. Itshould be appreciated that such a water bypass increases the flow rateof water through the washer orifice 140 and hence through the outlet 16of the water valve assembly 10 at relatively low inlet water pressuressuch as 10-20 psi.

[0051] However, at higher inlet water pressures (e.g., greater than 20psi), such a water bypass is not needed. In particular, at waterpressures greater than, for example, 20 psi, the flow control device 50flexes or deforms in response to variations in inlet water pressureexerted on the upstream face 56 thereof. In particular, as the inletwater pressure on the upstream face 56 increases, a greater amount offlexing or deformity of the flow control device 50 occurs therebyreducing the diameter of the central passage 54 and hence the water flowrate therethrough. As the inlet water pressure exerted on the upstreamface 56 decreases, the degree of flexing or deformity of the flowcontrol device 50 likewise decreases thereby enlarging, or evenmaximizing, the diameter of the central passage 54 and hence the waterflow rate therethrough. Hence, amongst other things, the size of thecentral passage 54 and the flexibility and/or deformability of thematerial utilized in the construction of the flow control device 50 maybe specifically selected to produce a flow control device which providesfor a specified, relatively constant flow rate.

[0052] It should be appreciated that at water pressures within thetypical household operative range (i.e. greater than 20 psi), theabove-described flexing and deforming of the flow control device 50 isadequate to produce the desired water flow rate without the use of thebypass channels 134. In fact, at certain higher water pressures, anadditional flow of water through the bypass channels 134 may increasethe water flow rate above the desirable level. The collapsible bypasspads 132 function to prevent such an undesirable bypass water flow athigher water pressures. In particular, once the water pressure exertedon the upstream face 56 exceeds a predetermined magnitude, each of thebypass pads 132 is compressed or otherwise collapsed into one of anumber of bypass recesses 142 which are each defined by a portion of thevalve body 12 and a portion of the washer 52. Such compression of thebypass pads 132 into the bypass recesses 142 causes the sealing surface136 defined in the sealing lip 126 of the flow control device 50 to beadvanced into sealing engagement with the shoulder 138 of the bypasschannels 134 thereby preventing the flow of water through the bypasschannels 134. It should be appreciated that the portions of the sealinglip 126 which are not proximate to the bypass channels 134 remain insealing engagement with the interior valve body walls of the centralcavity 42 irrespective of the inlet water pressure.

[0053] Therefore, when the portions of the sealing lip 126 proximate tothe bypass channels are urged into sealing engagement with therespective shoulders 138 of the bypass channels 134 in the mannerdescribed above, the entire periphery of the flow control device 50 isin sealing engagement with the valve body 12 thereby preventing the flowof any water around the periphery of the flow control device 50 suchthat any water being advanced through the washer orifice 140 of thewasher 52 (and hence through the water outlet 16) must first be advancedthrough the central passage 54 of the flow control device 50. In thismanner, the flow rate of water advancing through the flow control devicemay be maintained relatively constant based on the aforedescribedflexing and deformation of the flow control device 50.

[0054] Although the bypass channels 134 are herein described as beingdefined in the valve body 12, and have significant advantages thereby inthe present invention, it should be appreciated that otherconfigurations of the bypass channels 134 are contemplated for use inthe present invention. For example, a valve component such as acup-shaped member having the bypass channels 134 defined therein may beinserted into the central cavity 42 of the valve body 12. At the closedend thereof, the cup-shaped member has an orifice defined therein forallowing water to be advanced out of the central cavity of thecup-shaped member. In such a configuration, the flow control device 50would be positioned within a central cavity of the cup-shaped member inorder to cooperate with the bypass channels 134 in the manner describedabove. It should be appreciated that such use of a separate valvecomponent (i.e. the cup-shaped member) is particularly useful forretrofitting existing water valve assembly designs which do not includea valve body having bypass channels defined therein.

OPERATION OF THE PRESENT INVENTION

[0055] In operation, the water valve assembly 10 may be utilized toprovide for a relatively constant water flow rate at varying water inletpressures. In particular, at relatively low inlet water pressures (e.g.,less than 20 psi), the flow control device 50 assumes a low pressureorientation in which the sealing surface 136 defined in the sealing lip126 of the flow control device 50 is spaced apart from a shoulder 138 ofthe bypass channels 134 (see FIGS. 7, 8, 9, and 11). This allows therelatively low pressured water advancing through the central cavity 42of the valve body 12 to not only advance through the central passage 54of the flow control device 50, but also advance through the bypasschannels 134. It should be appreciated that such a water bypassincreases the flow rate of water through the washer orifice 140 andhence through the outlet 16 of the water valve assembly 10 at relativelylow inlet water pressures such as 10-20 psi.

[0056] However, at higher inlet water pressures (e.g., greater than 20psi), the flow control device 50 is oriented in a high pressureorientation in which the collapsible bypass pads 132 function to preventan undesirable bypass water flow. In particular, once the water pressureexerted on the upstream face 56 exceeds a predetermined magnitude, eachof the bypass pads 132 is compressed or otherwise collapsed into one ofthe bypass recesses 142. Such compression of the bypass pads 132 intothe bypass recesses 142 causes the sealing surface 136 defined in thesealing lip 126 of the flow control device 50 to be advanced intosealing engagement with the shoulder 138 of the bypass channels 134thereby preventing the bypass flow of water through the bypass channels134. It should be appreciated that the portions of the sealing lip 126which are not proximate to the bypass channels 134 remain in sealingengagement with the interior valve body walls of the central cavity 42irrespective of the inlet water pressure. Therefore, when the portionsof the sealing lip 126 proximate to the bypass channels 134 are urgedinto sealing engagement with the respective shoulders 138 of the bypasschannels 134 in the manner described above, the entire periphery of theflow control device 50 is in sealing engagement with the valve body 12thereby preventing the flow of any water around the periphery of theflow control device 50 such that any water being advanced through thewasher orifice 140 of the washer 52 (and hence through the water outlet16) must first be advanced through the central passage 54 of the flowcontrol device 50.

[0057] In this manner, the flow rate of water advancing through the flowcontrol device may be maintained relatively constant based on theflexing and deformation of the flow control device 50. In particular, asthe inlet water pressure exerted on the upstream face 56 increases, agreater degree of flexing or deformity of the flow control device 50occurs thereby reducing the diameter of the central passage 54 and hencethe water flow rate therethrough. As the inlet water exerted on theupstream face 56 decreases, the degree of flexing or deformity of theflow control device 50 likewise decreases thereby enlarging, or evenmaximizing, the diameter of the central passage 54 and hence the waterflow rate therethrough.

[0058] Hence, from the above description it should be appreciated thatthe configuration of the flow control device 50 and the valve body 12may be altered to fit the needs of a given water valve assembly design.In particular, the size, number, and material construction of the bypasspads 132 may be altered to adjust the pressure at which the sealing lip126 is advanced into sealing engagement with the respective shoulders138 of the bypass channels 134 in order to prevent water from bypassingthe flow control device 50. In particular, by increasing the number orsize or the bypass pads 132, or constructing them from relativelyrigidly deformable materials, the pressure at which the bypass channels134 are sealed by the sealing lip 126 may be increased. Alternatively,by decreasing the number or size of the bypass pads 132, or constructingthem from a relatively soft deformable material, the pressure at whichthe bypass channels 134 are sealed by the sealing lip 126 may bedecreased.

[0059] Moreover, the size and number of the bypass channels 134 may bealtered in order to alter the amount of water which is allowed to bypassthe flow control device 50. In particular, by increasing the size andnumber of bypass channels 134, the amount of water which is allowed tobypass the flow control device 50 (when the by pass channels 134 are notsealed by the sealing lipl26) likewise increases. Conversely, bydecreasing the size and number of the bypass channels 134, the amount ofwater which is allowed to bypass the flow control device 50 is likewisedecreased.

[0060] While the invention has been illustrated and described in detailin the drawings and foregoing description, such an illustration anddescription is to be considered as exemplary and not restrictive incharacter, it being understood that only the preferred embodiments havebeen shown and described and that all changes and modifications thatcome within the spirit of the invention are desired to be protected.

[0061] There are a plurality of advantages of the present inventionarising from the various features of the water valve assembly describedherein. It will be noted that alternative embodiments of the water valveassembly of the present invention may not include all of the featuresdescribed yet still benefit from at least some of the advantages of suchfeatures. Those of ordinary skill in the art may readily devise theirown implementations of a water valve assembly that incorporate one ormore of the features of the present invention and fall within the spiritand scope of the present invention as defined by the appended claims.

[0062] For example, the concepts of the present invention may beutilized in the construction of other types of water valve assemblies.In particular, as shown in FIG. 12, the concepts of the presentinvention may be utilized in the construction of a water valve assembly10′ which has a pair of water outlets 16 and 16′ (as opposed to a singlewater outlet). Such a valve assembly is particularly useful forsupplying water to two separate appliance components such as an icemakerand a door-mounted cold water dispensing unit. Moreover, it should alsobe appreciated that the concepts of the present invention may also beutilized in the construction of water valve assemblies for use in othertypes of appliances such as dishwashers and clothes washers or even inthe construction of water valve assemblies for non-applianceapplications.

[0063] As a further example, the water valve assemblies 10, 10′ of thepresent invention may also be constructed to include additional novelvalve components. For example, as shown in FIGS. 13-19, the water valveassembly 10 (and also the water valve assembly 10′) may be constructedwith a single component which performs the function of both the filterscreen 46 and the noise suppressor 48 (hereinafter designated withreference numeral 150). Such use of an integrated filter and noisesuppressor 150 provides numerous advantages to the water valveassemblies 10, 10′. In particular, by reducing the number of componentsassociated with the valve assemblies 10, 10′, manufacture of the valveassemblies is simplified thereby reducing costs associated with thevalve assemblies.

[0064] The integrated filter and noise suppressor 150 is preferablyconstructed of a polymeric material such as plastic and includes acomponent body 152 having a number of screen members 154 and a number offluid channels 156 defined therein. As shall be discussed in greaterdetail below, water is first advanced through a number of gaps 158defined between the screen members 154 so as to remove any particlessuspended in the water and thereafter advanced through the fluidchannels 156 prior to advancement through the flow control device 50.Such a flow arrangement effectively filters the water flow while alsoreducing, or even eliminating, cavitation within the flow of waterthereby reducing the noise associated with water flow through the valveassembly 10,10′.

[0065] As shown in FIG. 13, the component body 152 of the integratedfilter and noise suppressor 150 is sealingly engaged with the interiorwalls of the central cavity 42 of the valve body 12. In particular, asealing flange 174 defined in the component body 152 around the outerperiphery of a downstream end portion 182 of the body 152 (see alsoFIGS. 14-16, 18, and 19) contacts the interior walls of the centralcavity 42 so as to prevent water from being advanced around theperiphery of the component body 152. As a result, a large portion of thewater advancing through the central cavity 42 of the valve body 12 isadvanced into a fluid cavity 162 defined in the component body 152 ofthe integrated filter and noise suppressor 150 (see FIGS. 15 and 17).Water advancing into the fluid cavity 162 strikes a bullet-shaped fluiddiverter 164 which directs the water radially outwardly in alldirections.

[0066] The outwardly directed flow of water (from the fluid diverter164) is then advanced through the gaps 158 between the screen members154 so as to filter the flow of water or otherwise inhibit any debrisparticles which may be contained in the incoming residential water flowfrom further advancement through the remaining valve componentsassociated with the water valve assembly 10, 10′. Once advanced throughthe gaps 158 between the screen members 154, the flow of wateraccumulates in a number of fluid reservoirs 166 (see FIG. 13) defined bythe area between (1) a number of sidewalls 168 of the component body 152into which the fluid channels 156 are defined (see FIGS. 14 and 15), (2)the outer surface of the screen members 154, (3) a downstream face 170of the an upstream flange 188 (see FIGS. 13 and 14) defined in thecomponent body 152, (4) an upstream face 172 of the sealing flange 174(see FIGS. 13, 15, 18, and 19), and (5) the sidewalls of the centralcavity 42 of the valve body 12.

[0067] It should be appreciated that a relatively small portion of thewater flowing through the water valve assemblies 10,10′ is advanceddirectly into the fluid reservoirs 166. In particular, the upstreamflange 188 has a number of filtering orifices 186 defined therein (seeFIGS. 16 and 17). Water may be advanced directly into the fluidreservoirs 166 through the filtering orifices 188 without first beingadvanced through the fluid cavity 162 defined in the component body 152.

[0068] In any event, water is then allowed to flow from the fluidreservoirs 166, through a number of access openings 176 defined in thesidewalls 168 of the component body 152 (see FIGS. 13,16, 18, and 19),and into the fluid channels 156. Once into the fluid channels 156, wateris advanced therethrough and exited out a number of exit openings 180(see FIG. 14) and into a portion 178 of the central cavity 42 (see FIG.13) which houses the flow control device 50 (note that the flow controldevice 50 has been removed from FIG. 13 for clarity of description).

[0069] As described, the configuration of the integrated filter andnoise suppressor 150 creates a complex flow path which effectivelyfilters the flow of water while also reducing the incidences ofcavitation within the water thereby reducing the noise associated withthe flow of water as it advances through the water valve assembly10,10′.

What is claimed is:
 1. A water valve assembly, comprising: a valve bodyhaving defined therein (i) an inlet, (ii) an outlet, (iii) a centralcavity, and (iv) a component access opening, wherein fluid advancinginto said valve body through said inlet must pass through said centralcavity before exiting out of said valve body through said outlet, andfurther wherein said component access opening is configured so that avalve component may be advanced into said central cavity through saidcomponent access opening; and a retaining bracket having a retainingportion positioned in relation to said valve body so as to blockadvancement of said valve component from said central cavity to alocation outside of said valve body through said component accessopening.
 2. The water valve assembly of claim 1, wherein: said valvebody further has defined therein a bracket-receiving opening, and saidretaining portion of said retaining bracket extends through saidbracket-receiving opening.
 3. The water valve assembly of claim 1,wherein: said valve body further has defined therein a firstbracket-receiving opening and a second bracket-receiving opening spacedapart from each other, said retaining portion of said retaining bracketextends through said first bracket-receiving opening and said secondbracket-receiving opening.
 4. The water valve assembly of claim 3,wherein an intermediate part of said retaining portion of said retainingbracket is interposed between said first bracket-receiving opening andsaid second bracket-receiving opening.
 5. The water valve assembly ofclaim 4, wherein: said retaining portion of said retaining bracketincludes an elongated member, said elongated member extends through saidfirst bracket-receiving opening and said second bracket-receivingopening, and a distal end portion of said elongated member is crimpedwhereby advancement of said elongated member through said firstbracket-receiving opening and said second bracket-receiving opening isinhibited.
 6. The water valve assembly of claim 1, wherein: saidretaining bracket further includes a pair of lateral legs defining aspace therebetween, said retaining portion of said retaining bracketincludes a central leg positioned within said space, and a part of saidvalve body which defines said component access opening is alsopositioned within said space.
 7. The water valve assembly of claim 6,wherein said central leg extends through said first bracket-receivingopening and said second bracket-receiving opening.
 8. The water valveassembly of claim 6, wherein: said valve body defines a shoulder, eachof said pair of lateral legs includes a crimped distal end portion, andmovement of said retaining bracket in relation to said valve body isinhibited due to physical contact between said crimped end portion andsaid shoulder.
 9. The water valve assembly of claim 1, wherein saidretaining portion of said retaining bracket is positioned in contactwith said valve component.
 10. A water valve assembly, comprising: avalve body having defined therein (i) an inlet, (ii) an outlet, (iii) acentral cavity, and (iv) a component access opening, wherein fluidadvancing into said valve body through said inlet must pass through saidcentral cavity before exiting out of said valve body through saidoutlet, and further wherein said component access opening is configuredso that a valve component may be advanced into said central cavitythrough said component access opening; a fitting at least partiallypositioned within said inlet of said valve body; and a retainer having(i) a first retaining portion positioned in relation to said valve bodyso as to block advancement of said valve component from said centralcavity to a location outside of said valve body through said componentaccess opening, and (ii) a second retaining portion positioned inrelation to said fitting so as to block advancing of said fitting in adirection away from said inlet.
 11. The water valve assembly of claim10, wherein: said valve body further has defined therein abracket-receiving opening, and said retaining portion of said retainingbracket extends through said bracket-receiving opening.
 12. The watervalve assembly of claim 10, wherein: said valve body further has definedtherein a first bracket-receiving opening and a second bracket-receivingopening spaced apart from each other, said retaining portion of saidretaining bracket extends through said first bracket-receiving openingand said second bracket-receiving opening.
 13. The water valve assemblyof claim 12, wherein an intermediate part of said retaining portion ofsaid retaining bracket is interposed between said firstbracket-receiving opening and said second bracket-receiving opening. 14.The water valve assembly of claim 13, wherein: said retaining portion ofsaid retaining bracket includes an elongated member, said elongatedmember extends through said first bracket-receiving opening and saidsecond bracket-receiving opening, and a distal end portion of saidelongated member is crimped whereby advancement of said elongated memberthrough said first bracket-receiving opening and said secondbracket-receiving opening is inhibited.
 15. The water valve assembly ofclaim 10, wherein: said retaining bracket further includes a pair oflateral legs defining a space therebetween, said retaining portion ofsaid retaining bracket includes a central leg positioned within saidspace, and a part of said valve body which defines said component accessopening is also positioned within said space.
 16. The water valveassembly of claim 15, wherein said central leg extends through saidfirst bracket-receiving opening and said second bracket-receivingopening.
 17. The water valve assembly of claim 15, wherein: said valvebody defines a shoulder, each of said pair of lateral legs includes acrimped distal end portion, and movement of said retaining bracket inrelation to said valve body is inhibited due to physical contact betweensaid crimped end portion and said shoulder.
 18. The water valve assemblyof claim 10, wherein said retaining portion of said retaining bracket ispositioned in contact with said valve component.
 19. The water valveassembly of claim 10, wherein: said second retaining portion includes afitting opening through which said fitting extends, said fittingincludes a flange, and said second retaining portion contacts saidflange when said fitting is extending through said fitting opening. 20.A water valve assembly, comprising: a valve body having an inlet and acomponent access opening defined therein; a fitting at least partiallypositioned within said inlet; and a retainer having (i) a firstretaining portion positioned to retain a valve component within saidcomponent access opening, and (ii) a second retaining portion positionedto retain said fitting within said inlet.
 21. The water valve assemblyof claim 20, wherein: said first retaining portion is positioned incontact with said valve component, and said second retaining portion ispositioned in contact with said fitting.
 22. The water valve assembly ofclaim 20, wherein: said valve body further has an outlet and a centralcavity defined therein, and fluid advancing into said valve body throughsaid inlet must pass through said central cavity before exiting out ofsaid valve body through said outlet.
 23. A method, comprising: advancinga valve component into a central cavity of a valve body through acomponent access opening of said valve body; after said valve componentadvancing step, positioning a first portion of a retaining member incontact with said valve component so as to block advancement of saidvalve component from said central cavity to a location outside of saidvalve body through said component access opening; and after saidpositioning step, advancing fluid through said valve body from an inletof said valve body to an outlet of said valve body through said centralcavity.
 24. The method of claim 23, further comprising: before saidfluid advancing step, placing at least a part of a fitting in saidinlet; and after said placing step, positioning a second retainingportion of said retaining member in contact with said fitting so as toblock advancement of said fitting in a direction away from said inlet.25. The method of claim 23, wherein: said valve body further has definedtherein a retainer-receiving opening, and said first retaining portionextends through said retainer-receiving opening.